Automated mail handling apparatus



p 10, 1963 J. D. GOODELL ETAL AUTOMATED MAIL HANDLING APPARATUS 5 Sheets-Sheet 1 Filed Nov. 15, 1960 INVENTORS JOHN D. GOODELL EDWIN F. SHELLEY ATTORNEYS S p 1963 J. D. GOODELL ETAL AUTOMATED MAIL HANDLING APPARATUS 3 Sheets-Sheet 2 Filed Nov. 15, 1960 mmPhmJ N QI Sep 1 1963 J. D. GOODELL ETAL AUTOMATED MAIL HANDLING APPARATUS 3 Sheets-Sheet 3 Filed Nov. 15, 1960 n n n m INVENTQRS JOHN D. GOQDELL BY EDWIN F. SHELLEY rs 5&3 s53 r moEmfizoo l H60 m wozmeuzau wozwfihmm :5 v 81 8 8 .n. Q0258 5 mm 5 5 N: mm N: 6 2 51 w 2 5 r S. 5 ow M858 532 $23 22: 3 M58 5530 ATTORNEYS United States Patent C) AUTQMATEE MAIL H-LENG APPARATUS Jo n D: G andeur Silver p i M d n-F Shelley, New Rochelle, N.Y., assignors to US. Industries, line, New York, N.Y., a corporation of Dela-v ware 7 Filed Nov. 15, 1960, Ser. No. 69,380

8 Claims. (Cl. 214-11) The present invention relates to automated mail handling apparatus for the sorting, coding and distribution of addressed mail. More particularly, it relates to a unitary buffer apparatus which may be operatively associated alternatively with either a main mail distributing apparatus or with a separate and usually remote operating console. When associated with the console, the buffer apparatus is capable of mechanically storing in sequence arrangement a large quantity of addressed-envelope mail together with an electrically produced corresponding sequential coded record of the said addresses at the instance of the console operator. When associated with the main apparatus, the buffer apparatus is capable on signal demand of automatically delivering in coordinated sequence'the mail'and its coded addresses to the high speed sorting and distributing system of the main apparatus.

Recent surveys have indicated that mail volume in the United States is increasing exponentially as a function of population. Both automatic and semi-automatic machines of various types have been proposed as means for solving the enormous sorting and distribution problems imposed on the Post Offices both here and abroad. In specific applications where each piece of mail is addressed with a standard legible type, automatic reading machines may be employed to translatethe alpha-numeric address charactors on the pieces of mail into numerical codes which maybe used to control high speed sorting and distribution machines. Where an infinite variety of hand-writing must also be interpreted, however, the employment of human translators to operate semi-automatic mail-sorting machines is indicated. In one such semi-automatic mailsort-ing'machine that has been proposed, a plurality of modate the operating speed of the slowest operator and in turn the speedof the distributin-g machine must be synchronized with the opera-tors speed. The resultant overall operating efiiciency and speed-of'distribution is thereby drasticallyreduced below the desired optimum.

One of i the principal objects of the present invention optimum pace, not at a pace established by the main distributing machine or the slowest 'fellow worker. On subsequent :demand the apparatus provided by the invention is capable of sequentially delivering each piece of stored mail along with its proper address-code atan optimum speed which matches the maximum distribution speed of the main sorter.

A further object of the present invention is to provide herein.

intermediate mail storage apparatus as described above which is capable of automatically periodically checking the coordination of the delivered mail sequence with the delivered address code'sequence. The required integrity of a one-to-one correspondence between the two outputs to th mainsorter is maintained and long term cumulative errors or carryover of an errorthrough a long sequence of letters is thereby prevented. i

In accordance with a unique feature of the invention, the buffer apparatus is provided with means to automatically insert reference markers between adjacent predetermined pluralities of mail pieces when operatively associated with the console apparatus. Whenthe buffer apparatus is operatively associated with the main apparatus, the reference markers and recorded reference code signals are compared on a time basis to produce control signals which automatically maintain a one-to-one correspondence between the individual pieces of mail and the individual addresscodes as delivered. During the storage operating cycle, envelopes from a supply of faced and cancelled mail are sequentially delivered on a conveyor belt system to a viewing station at a codingconsole. The translator reads the address on each envelope and depresses an appropriate combination of keys to produce a predetermined address code signal. Eachaddress code signal is sequentially stored in a tape memory device and at the same time the letter is advanced to an intermediate bufier storage bin. A counter device is provided which auto matically produces a reference code signal after a predetermined plurality of envelopes have been coded and stored. Thereference. code signal from the counter is stored in the buffer tape memory and is also employed as a control signal to automatically insert a readily detectable reference marker in the sequentially stored envelopes.

The speed at which the humantranslator' completes th address interpretation and coding is completely within thecontrol of each individual operator. Thus it will be seen that'during the input storage cycle, the rate atwhich envelopes and their corresponding coded addresses are stored may be completely random. Regardless of the ma ture of the input coding and storage rate, reference markers are nevertheless inserted at predetermined envelope count intervals. Thus a reference marker may be inserted, for example, after every tenth envelope is placed into the intermediate storage bin. At the same time, the

output signal-developed by the'counter is recorded in the. tape memory system as a reference code signal.

After a desired volume of mail has been stored in the intermediate storage bin, the machine may be switched to operate as an automatic'mail feeding device wherein the stored mail and address codes are supplied: to a high speed sorting and distribution machine. These machines are well known in the prior art and will not'be described One such mail sorting machine is described in U.S. Patent 2,936,556 to H. T. Gibson. In the mail delivery cycle, the stored codes and the stored envelopes, are deliveredfio the main sorting machine in the same sequence in which they were stored. A sensing device is provided adjacent the output deliyery path which produces an output reference marker signal with the passage of each reference marker; The reference marker signal is compared on a time basis with an output signal from the tape memory system which is produced periodically by the stored reference code. As long as these tworeference; signals are produced in time. coincidence, sequential delivery of the stored envelopes and-sequential delivery ofthe stored address codes (from the tape-memory) continue uninterrupted. to the main sorter. Ifforany reason-the two reference signals fall-out of time coincidence, the. intermittent delivery of the envelopes or the intermittent readout of the tape memory is accordingly halted for a sufficient interval of time to restore the decoding cons-ole.

a sired time coincidence. Thus, it Will be seen that the sequential outputs are automatically compared at predetermined periodic intervals in such a manner that long term cumulative errors or carryover of an error through a long sequence of envelopes is prevented.

The apparatus provided by the present invention has the advantage that individual operators may adjust their oper ating speeds to suit not only their own individual operating abilities but also to suit the nature of the addressed mail being stored. Where the addresses are distinctive or easily recognized because of the large volume of mail regularly distributed to the particular address, the operator is able to dispatch a number of envelopes to the storage bin very rapidly. On the otherhand, where the address is illegible or infrequently encountered in the distribution process, the individual operator may slow up the coding process. It will be recognized by those skilled in the art that the apparatus provided by the present invention affords greater operating efficiency and accuracy than the semi-automatic mail sorting apparatus proposed in the prior art.

Other objects of the invention will be pointed out in the following description and claims and illustrated in the accompanying drawings, which disclose, by way of example, the principles of the invention and a preferred embodiment thereof for applying those principles. In the drawings:

FIG. 1 is a perspective view of mail sorting apparatus incorporating the features of the invention;

FIG. 2. isa diagrammatic representation of the apparatus shown in FIG. 1 illustrating operation during the input storage cycle; and

FIG. 3 is a diagrammatic representation of the apparatus of FIG. 1 showing the operation thereof during the output delivery cycle.

Referring to FIG. 1, there is shown a plurality of intermediate mobile storage consoles positioned adjacent a coding console 11. Envelope 12 is carried'to a viewing station in front of translating operator 13 on a conveyor belt from a supply of cancelled and faced envelopes (not shown). The operator upon reading each address on the envelope to be stored depresses an appropriate combination of keys on keyboards 15 and 16 to produce a desired address code which is stored in tape memory 17. The envelopes are delivered through input port 7 during the storage cycle and stored in a step-by-step sequence within the storage console 16. After a desired volume of mail has been stored in the storage console, the console is rolled on casters to a position adjacent the main mail distribution machines 20. The storage consoles are rapidly positioned with respect to the main sorting machines by index pins (not shown) adapted to engage pin receptacles 21. Electrical connections between the main sorting machines and the intermediate storage consoles 10 are completed through electrical connector 22. Mail is delivered from the console 1G (through an output delivery port not shown) to the main distributing machine via delivery port 2 3.

A simplified diagrammatic drawing illustrating the operation of the present invention during the mail storage cycle is shown in FIG. 2. Envelope 12 is conveyed in front of the operator between guide walls 8 and 51 by conveyor belt 30 which is driven by motor 31 via magnetic clutch 32. Motor 31 is advantageously a variable speed type and conventional operator controls (not shown for purposes of simplification) for controlling the speed of the motor and the operation of the clutch are provided at the A predetermined address code, which is advantageously in binary number form, is produced in the coding console when the operator" depresses a desired combination of keys on keyboards 15 and 16. The ad- .dress code signal is supplied to tape memory 17 via conductor 35 as shown. Tape memory 17 is advantageously of the multiple-track magnetic type and the drive motor for record and playback is aconventional type which adductor 38 each time a combination of keys is depressed;

Counter 37 may be any one of a number of well-known counter circuits which produce an output signal after having received a predetermined number of input signals (e.g., 10) via conductor 38. Counter 37 is in effect a divider circuit which produces one output signal after it has received a given number of input signals from the coding console. The counter output signal is supplied via conductor 40 to tape memory 17 as a reference code signal where it is recorded on a separate track. A counter output signal is also supplied to the actuating coil of relay 41 via conductor 42. When relay 41 is energized by the counter signal, switch contacts are closed which energize spring-loaded solenoid 50 via conductor 49 causing the vacuum pickup plate 51 to move from its normal rest position above the letter guide-Walls 8 and 9 to a position in contact with the forward reference marker 55. Container 56 is provided to store the reference markers and a spring-loaded pressure plate 53 is provided to urge the reference markers in a forward diection against flexible retaining fingers 57. The arm of microswitch 60, which is normally in contact with the rear surface of pickup plate 51, is released when solenoid 50 is energized and the switch arm therein is displaced from a normally open contact position to a closed contact position. Thus, switch 60 functions to energize the solenoid coil in valve 61. Valve 61 is thereby moved from a normally closed .-position to an open position which connects vacuum supply 62. to the open perfora-, tions 65 on the face of pickup plate 51. The vacuum action is employed to remove reference marker 55 from container 56 and when solenoid 50 is de-energized, springloaded pickup plate 51 is caused to return to its normal rest position as shown. Microswitch 61 is thereby opened and the vacuum supply to the pickup plate is turned off. With the removal of the vacuum supply, the reference marker is dropped onto conveyor belt 70 which is driven by motor 71. Conveyor belt 70 is advantageously driven at a relatively high speed with respect to conveyor belt 30 so that letters delivered from the coding console following the coding operation are rapidly moved to the letter storage bin '72. The letters and reference markers are stacked vertically in a flat horizontal position as shown. The necessary rotation required to displace the envelopes from the normal vertical travelling position is effected by duct 75 which has a twist as shown.

FIG. 3 is a diagrammatic drawing showing the operation of the apparatus provided by the present invention during .the mail feeding or mail delivery cycle. During this portion of the operating cycle, the storage console, including the mail storage bin 72 and the tape memory 17, is positioned adjacent to the main sorting and distributing machines 20 (see FIG. 1). Thetape memory is rewound to the starting position corresponding to the first recorded address for the first letter stored in bin 72, and the tape recorder is switched to playback position. The tape memory is equipped with a plurality of conventional tape heads which are adapted to read out the address codes which have been stored in the tape memory during the above-described mail storage cycle of operation. A seppointed out above, drive synchronization alone is not sufiicient to insure an exact one-to-one correspondence be.-

tween each letter delivered and each coded address de- Inaccordance with a featured aspect of the invention,

circuit apparatus is provided for comparing the absolute position of the periodically inserted dummy reference markers with the corresponding reference codes stored in the tape memory. The speed at which the envelopes and address codes are delivered to the main sorting machine is determined by the rate or the frequency at which power is supplied from power source 80 through switch contacts on relay 90 and conductor 81 to the tape machine and through switch contacts on relay 91 and conductor 82 to solenoid 92. The repetition rate at which power is supplied by power source 80 is advantageously made adjustable so that the output delivery rate of address codes and envelopes can be matched to the distribution rate for the main mail sorting machine. Power source 30* may, for example, comprise a variable speed motor driving a cam actuated switch or a brush and commutator type switch. Inthe normal mode of operation, the switch contacts on relays 90, and 91 are normally closed and power is periodically supplied to solenoid 92 and to the indexing drive motor for tape memory 17. The coil on solenoid actu-' 'ated valve 93 is also energized (via conductor 32) thereby connecting vacuum supply, 94 to the perforations 95 on the upper surface of the letter pickup plate 96 via flexible hose 98. The resulting vacuum actionpulls the lowermost marker orenvelope past retaining fingers 97 to the pickup plate and energized solenoid 92 displaces plate Q6 to an extended position over the output delivery chute 84. When the electrical power is removed from 92 and 93, the vacuum is disconnected from perforations 95 and the spring-loaded pickup plate is returned to its normal position as shown. Brush 100 is adapted to remove the envelope or marker from the pickup plate on its return passage. The vacuum is sufficiently strong to hold the letter. on the pickup plate on the outgoing passage.

-Thedummy reference markers which are periodically inserted between the stored envelopes during the storage cycle are made of a material which is easily distinguished from conventional envelopes by well-known electronic techniques. In the preferred embodiment of the invention, these reference markers are made of metal which is sensed by metal detector 110- mounted on the pickup plate. Detectors which sense a change in reactance produced by the passage of a metallic object near an inductor or capacitor are well known in the art and will not be described herein. An output signal is supplied to amplifier 111 via conductor 113 when a reference marker is held on plate 96 over the detector. The output signal is thereby amplified and supplied to solenoid 115 via conductor 116 and to coincidence comparator 120 via conductor 121. Comparator 126 may comprise, for example, a pair of conventional anti-coincidence or inhibitor circuits which are will known and will not be described herein. Solenoid 115 is arranged to open trap door 125 when energized by the amplified detector signal causing each reference marker 112 to drop into collecting bin 13-0. The trap door remains closed when conventional envelopes pass over detector 110 and the envelopes are thereby delivered to the main mail sorter conveyor system through output delivery port 132.

When the amplified detector signal (reference marker) is supplied to the comparator 120 in time coincidence with the reference code signal supplied via conductor 135 from the tape memory, both the tape memory and the solenoid driven pickup member continue to operate in proper uninterrupted synchronism. Should something happen during the normal course of operation which disrupts the proper phase synchronization or time coincidence between the stored reference code signal and the reference marker signal, the coincidence comparator 12%) functions to correct the error in sequence synchronization. If the reference code signal is delivered to the coincidence coparator first, a sequence error signal is supplied via conductor 136 to the coil of relay causing the power to be removed from the tape memory indexing motor. In the meantime, power is continually supplied to the solenoid-driven pickup arm and the required number of envelopes will be delivered until the desired marker reference is picked'up and'sensed by the detector. The error signal is thereupon removed from conductor 136 and power is again restored to the indexing motor of tape'memory 17.. When the reference marker reachesdetector before the reference code is suppliedto the coincidence comparator, a sequence error control signal is then delivered via conductor 137 to the actuating coil of, relay 91. The distribution of letters is thereby halted until the tape memory is advanced a sufficient number of steps to produce the desired reference code signal. The error control signal supplied to the actuating coil of relay 91 is then removed and power is once again restored to the solenoids of the letter delivering mechanism.

While a preferred embodiment of the invention has been shown and described, numerous variations and modifications will occur to those skilled in the art. For ex-. ample, a conventional optical. type sensing devicemay be employed to detect the periodically inserted reference markers. Equivalent mechanical sensing devices may also be employed to develop the reference marker signal. While solenoid actuated vacuum pickup plates have been shown as means for transfering' individual reference markers and envelopes, it will. be apparent that other equivalent mechanical arrangements may be employed. We claim: X

1. Automated mail handling apparatus comprising the combination of a code record actuated high speed addressed mail main sorting and distributing system and apparatus, coding console means separate from and operatively diassociated with said main apparatus and whereat addressed mail may be serially observed and address coded in recorded sequence with regularly and automatically interposed reference markers between each of a predetermined plurality of mail pieces, a mobile buffer unitary apparatus adapted to be operatively associated alternatively with said main apparatus and with said coding console, said buffer apparatus being adapted to mechanically'store addressed mail in said coded record sequence and having means to automatically insert reference markers between adjacent predetermined pluralities of mail pieces when operatively associated with said coding console and to automatically deliver said mail in said coded record sequence into the main apparatus when operatively associated with the latter, said buffer storage-console having means to maintain a one-to-one corespondence between the individual pieces of mail delivered and the individual coded address delivered, and to remove the said referenec markers from the delivered pieces of mail.

2. Automated mail handling apparatus having an input storage cycle for sequentially storing pieces of mail on a time coordinated basis along with the coresponding address information for each piece of mail, and having an automatic output delivery cycle for sequentially delivering both the stored pieces of mail and the corresponding stored address information on a time coordinated basis to an automatic mail distributing machine, said apparatus comprising in combination, an input receiving port and an output delivery port, means operable during said input' storage cycle to convey individual pieces of mail from said input port to a viewing station, selectively operable means adapted to be controlled by a human operator during the storage cycle to produce a predetermined code signal corresponding to the address on each piece of mail to be sequentially stored, storage means adapted to sequentially record address code signals produced during the input storage cycle and sequentially reproduce said recorded code signals to produce output address signals during the output delivery cycle, means adapted to sequentially store the pieces of mail received during .the said storage operating cycle, means operable during said input storage cycle to convey the individual pieces of mail from said viewing station to said mail storage means, and means operable during said output delivery operating cycle for sequentially transferring the pieces of mail from said mail storage means to said output delivery port in time coordination with the production of corresponding output address signals.

3. Automated mail handling apparatus having an input storage cycle for sequentially storing pieces of mail on a time coordinated basis along with the correspond ingaddress information for each piece of mail, and having an automatic output delivery cycle for sequentially delivering both the stored pieces of mail and the corresponding stored address information on a time coordinated basis to an automactic mail distributing machine, said apparatus comprising in combination, an input receiving port and an output delivery port, means operable during said input storage cycle to convey individual pieces of mail from said input port to a viewing station, selectively operable means adapted to be controlled by a human operator during the storage cycle to produce a predetermined code signal corresponding to the address on each piece of mail to be sequentially stored, counter means operable during said input storage cycle for periodically producing a reference code signal after a predetermined number of address code signals have been produced, a supply source of dummy reference markers, means responsive to said reference code signal for in serting a single reference .marker between pieces of sequentially stored mail, storage means adapted to sequentially record said address code signals and said reference code signals during the input storage cycle and sequentially reproduce the recorded code signals to produce output address signals and output reference code signals respectively during the output delivery cycle, mail storage means adapted to sequentially store the pieces of mail and the reference markers inserted during the said storage operating cycle, means operable during said output delivery cycle for sequentially transferring the pieces of mail and the reference markers from said mail storage means to said output delivery port in time coordination with the production of corresponding output address signals, detector means for producing a reference marker signal in response to ithe transfer of a reference marker to said output delivery port, comparator means responsive to said output reference-code signals and said reference marker signals for producing a sequence error signal when a disparity in time coincidence obtains between the respective reference signals, and means responsive to said sequence error signal forautomatically restoring timecoincidence between said output reference code signals and said reference marker signals, whereby a one-to-one correspondence is maintained between the output address signals and the pieces of mail delivered to the said output delivery port.

4. The automated mail handling apparatus of claim 3 in which the dummy reference markers are metallic and said detector includes a metal-sensing reactance element.

5. Automated mail handling apparatus for sequentially storing pieces of mail on a time coordinated basis along with the coresponding address information for the said pieces of mail, said apparatus comprising in combination, an input port for receiving pieces of mail to be stored for subsequent automatic distribution, means for conveying individual pieces of'mail from said input port to a viewing station, selectively operable means adapted to be controlled by a human operator to produce a predetermined code signal corresponding to the address on each piece of mail conveyed to said viewing station, means forsequentially storing the said pieces of mail, means for conveying the individual pieces of mail from the said viewing station to said mail storing means, counter means for periodically producing a reference code signal after a predetermined number of mail pieces vhave been stored, a supply source of dummy reference markers, means responsive to said reference code signal for inserting a single reference marker between pieces of sequentially stored mail, storage means adapted to sequentially record said address code signals and said reference code signals in a form suitable for subsequent sequential reproduction.

6. The automatic mail handling apparatus of claim 3 in which circuit means responsive to said sequence error Z'signal are provided for advancing or retarding the sequential production of address code signals with respect to the sequential transfer of mail to the output delivery port, whereby time coincidence between the respective reference signals is automatically maintained.

-7. The automated mail handling apparatus of claim 2 in which a multiple track magnetic tape is provided to record and reproduce address code signals.

8. The automated mail handling appartus of claim 3 in which means responsive to said reference marker signal are provided for diverting the transfer of dummy reference markersfrom the output delivery port to an auxiliary collecting bin.

References Cited in the file of this patent UNITED STATES PATENTS 2,936,556 Gibson May 17, 1960 FOREIGN PATENTS 632,403 Great Britain Nov. 28, 1949 

1. AUTOMATED MAIL HANDLING APPARATUS COMPRISING THE COMBINATION OF A CODE RECORD ACTUATED HIGH SPEED ADDRESSED MAIL MAIN SORTING AND DISTRIBUTING SYSTEM AND APPARATUS, CODING CONSOLE MEANS SEPARATE FROM AND OPERATIVELY DIASSOCIATED WITH SAID MAIN APPARATUS AND WHEREAT ADDRESSED MAIL MAY BE SERIALLY OBSERVED AND ADDRESS CODED IN RECORDED SEQUENCE WITH REGULARLY AND AUTOMATICALLY INTERPOSED REFERENCE MARKERS BETWEEN EACH OF A PREDETERMINED PLURALITY OF MAIL PIECES, A MOBILE BUFFER UNITARY APPARATUS ADAPTED TO BE OPERATIVELY ASSOCIATED ALTERNATIVELY WITH SAID MAIN APPARATUS AND WITH SAID CODING CONSOLE, SAID BUFFER APPARATUS BEING ADAPTED TO MECHANICALLY STORE ADDRESSED MAIL IN SAID CODED RECORD SEQUENCE AND HAVING MEANS TO AUTOMATICALLY INSERT REFERENCE MARKERS BETWEEN ADJACENT PREDETERMINED PLURALITIES OF MAIL PIECES WHEN OPERATIVELY ASSOCIATED WITH SAID CODING CONSOLE AND TO AUTOMATICALLY DELIVER SAID MAIL IN SAID CODED RECORD SEQUENCE INTO THE MAIN APPARATUS WHEN OPERATIVELY ASSOCIATED WITH THE LATTER, SAID BUFFER STORAGE CONSOLE HAVING MEANS TO MAINTAIN A ONE-TO-ONE CORESPONDENCE BETWEEN THE INDIVIDUAL PIECES OF MAIL DELIVERED AND THE INDIVIDUAL CODED ADDRESS DELIVERED, AND TO REMOVE THE SAID REFERENCE MARKERS FROM THE DELIVERED PIECES OF MAIL. 